2005 5.0 Carbed Low Fuel Pump Voltage

205BR

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Jul 8, 2010
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Hey all,
Long-time lurker, rare poster here! I am having a fit with my 5.0 Thunderbolt V carbed engine which is in a Bayliner 205. The current issue at hand is that I am only receiving around 7 volts to my fuel pump, but here is the backstory.

Bat sat in my driveway (covered) and we got a ton of rain. Changed oil and filter/fuel filter, as well as new spark plugs. Went to start the engine on muffs one more time before I put it in the water and the engine would begin to turn over and then make a heavy "clunk" that sounded like hydrolock. Engine would eventually fire, but was running awful. Pulled plugs, disconnected fuel pump power at the pump (previous owner installed a quick-connect plug thing), and spun the engine over with the starter to check for water in cylinders. Did not find any, so discovered that the distributor cap had TONS of moisture in it. Dried that out (and temporarily removed the gasket, getting a new one tomorrow morning),put the cap on, reinstalled plugs, and reconnected the fuel pump. Cranked the motor over and it fired right up and ran for about 45 seconds, which I am assuming is just from leftover gas in the system. Then the motor died.

Now, this is where it gets a little sketchy, and I know it is not right, but for now I am playing the cards I am dealt. The previous owner also installed some sort of bypass to the slave solenoid (i think?, because the boat used to just click when trying to start it) instead of replacing it. Essentially, up until this point, the fuel pump has activated whenever the key is in Key-On-Engine-Off position, so I guess you could say it has been straight wired. Now that the boat is all back together, the pump is not running. Took my multimeter to the connections, and am only getting a reading of ~7 volts. Oil pressure is 35-38 when cranking, and motor is turning over very strongly, battery has 12 volts. Where should I start looking in order to find the source of this low voltage? To me, it seems like a condition of a bad ground, but I don't even know where to start! Thanks so much!
 
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Fishermark

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Oct 19, 2003
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5,617
The fuel pump will receive its power directly from the starter solenoid till it starts, then it will run through an oil pressure switch. I would check all of your connections to make sure they are clean and corrosion free.
 

205BR

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Jul 8, 2010
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Awesome, I will start tracing those wires and see what I can find. Also, checked the voltage at the sending unit in the tank and it also is only showing ~6.5. Is this normal or should it be 12 as well?

Or, are the sending unit and pump both in the tank, and I have managed to screw up something else totally? Who knows.
 
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205BR

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Jul 8, 2010
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Okay, little update. Got 12V to the pump on Key On Engine Off, must have knocked a wire loose on the solenoid putting in plugs. Still only have 6.4 volts at the sending unit, and still do not have the "bzzzzz" from fuel pump upon turning to key-on engine-off. Could the time it took to fill the new fuel filter have fried the pump or tripped some protection curcuit?
 

alldodge

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Mar 8, 2009
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Howdy

The normal wiring of the electric fuel pump is it will receive 12V while cranking via the Yell/Pur wire, and after oil pressure builds up, the switch closes and send 12V via the Purple wire to keep it running.

Fuel Pump Wiring.jpg

Your getting 12V direct to the fuel pump because you said
Got 12V to the pump on Key On Engine Off

But then your next statement says
still do not have the "bzzzzz" from fuel pump

So your saying you have 12V at the fuel pump but the pump is not running?
 

205BR

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Jul 8, 2010
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Okay, got it all sorted and have good news! Yes, I was able to get 12v to the battery leads of the harness, but the pump would not operate. When I got the boat, there were a few rounds of electrical tape on the harness plug to the fuel pump. Turns out it is simply a loose-fitting plug. Turned the key to Key-On Engine-Off and fiddled with the connector, and the pump came to life! Even though the little "latch" is latched on the plug, I guess there is just enough play to keep from making a solid connection. I put a zip-tie squeezing the two ends together while I order a new plug. Turned the key and the boat fired right up! Thank you very much for the diagram and tips! Funny how so often it is the simple things getting in the way!
 
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